Method for treating aqueous solutions with weakly acidic cation exchange resins

ABSTRACT

A method for treating aqueous solutions by ion exchange uses a weakly acidic cation exchange resin and a strongly basic anion exchange resin to remove corrosion products and metal ion leakage from a solution while substantially reducing the quantity of acid required to regenerate the cation exchange resin. Substantial quantities of ammonia and other volatile amines are not removed from the solution during the treatment process.

TECHNICAL FIELD

The present invention relates to a method for treating aqueous solutions by ion exchange using a weakly acidic cation exchange resin and a strongly basic anion exchange resin to remove corrosion products and metal ion leakage from a solution while substantially reducing the quantity of acid required to regenerate the cation exchange resin. Substantial quantities of ammonia and other volatile amines are not removed from the solution.

BACKGROUND OF THE INVENTION

Ion exchange can be defined as the reversible interchange of ions between a solid (an ion exchange resin) and a liquid (usually an aqueous solution) in which there is no permanent change in the structure of the solid. Ion exchange resins are synthetic resins containing active substituents (usually sulfonic, carboxylic, phenolic, phosphonous, phosphonic or substituted amino groups) that give the resin the property of combining with or exchanging ions between the resin and a solution. For example, a cation exchange resin with active sulfonic groups in the hydrogen form will exchange its hydrogen ions with, for example, the sodium, calcium, magnesium and other metal ions present in water.

The customary procedure is to pass the liquid through a bed of the ion exchange resin, which is a granular and porous solid and has only a limited capacity for exchanging ions. When the useful exchange capacity of the cation exchange resin is exhausted, the resin can be regenerated with an acid, preferably a strong acid, which removes the accumulated metal ions. Simultaneously the cation exchange resin takes on an equivalent amount of hydrogen ions in exchange, thus restoring itself to the original hydrogen form. The acid generally used for this regeneration is dilute sulfuric acid. Hydrochloric acid is also an excellent, but usually more expensive, regenerant. An anion exchange resin can be regenerated with a strong base, such as sodium hydroxide.

Mixed bed systems and precoated filter systems containing both anion and cation exchange resins have been used in many industrial applications for the purification of aqueous solutions. A primary application of such systems is in the purification of water for condensate recirculation systems used to drive steam turbines. It is essential that the water be extremely pure to avoid any adverse effects on the surfaces of blades, boilers and pipes of the high pressure steam system. Since it is desired to produce water that is free of any residue upon evaporation, the cation exchange resin should preferably be in the hydrogen form, and the anion exchange resin should be in the hydroxide form.

As used herein, the term "bed" refers to a layer of filtration or ion exchange material, such as a column of ion exchange resin beads or a precoat layer, which has been deposited on a filter support including a filter screen, an annular filter cartridge, a film, a deep or shallow bed and the like. In general, a shallow bed is preferred over a deep bed so that the pressure drop within the bed is minimized thereby increasing the run length of the ion exchange process.

A particular problem with mixed bed ion exchange systems of the type conventionally employed is the production of ion "leakage," particularly sodium ion leakage. The term "leakage" refers to any ions that are not removed from the water by the ion exchange resin and, thus are permitted to "leak" past the ion exchange resin. As used herein, the term "leakage" also refers to any undesired ions, such as sodium, which are introduced into the water by elution of ions from the ion exchange resin which have not been removed during regeneration.

In a mixed bed system, the leakage problem arises primarily from the difficulty of obtaining perfect separation of the anion and cation exchange resins in the bed before regeneration of the ion exchange resins. As used herein, the term "separation" refers to the bulk classification of ion exchange resins within a single vessel or zone. As is familiar to those skilled in the art, such separation is usually accomplished by passing water upwardly through the ion exchange resins. This stream of water stratifies the mixture of the ion exchange resins by carrying the less dense strongly basic anion exchange resin to the top of the separation vessel, while the more dense weakly acidic cation exchange resin remains in the bottom portion of the vessel.

While the above method is effective for separating the bulk of the ion exchange resins, perfect separation cannot be achieved. A primary source of this difficulty is the ion exchange resin fines produced during handling of the ion exchange resins. Since upflow separation depends upon particle size along with density, the cation exchange resin fines will not sink to the bottom of the separation vessel, but will be carried upwardly with the strongly basic anion exchange resin. When the two ion exchange resins are subsequently isolated from one another, and the anion exchange resin is regenerated with sodium hydroxide, sodium ions will be introduced into the ion exchange sites in the cation exchange resin contaminant. When the ion exchange resins are returned to the service column, the sodium ions will be introduced into the water being treated, producing sodium leakage.

The leakage problem can be aggravated when substances such as ammonium hydroxide, ammonia or volatile amines are added even in trace amounts to the steam of a high pressure boiler or turbine system as is conventional to minimize corrosion. The ammonium ions gradually convert the cation exchange resin to the ammonium form and promote the release of sodium ions. Moreover, the amines often appear in the condensate and can reduce the capacity of the cation exchange resin to remove corrosion products and traces of ions produced by leakage from the condensate.

However, in certain applications it is desirable to remove only the corrosion products and the metal ions, while retaining the ammonia and volatile amines in solution. This allows the ammonia to be recycled in the system to reduce corrosion.

In addition, the use of a bed including a strongly acidic cation exchange resin requires the use of a large excess of fresh or unused acid to regenerate the resin. That disadvantage can be overcome, according to the present invention, by use of a weakly acidic cation exchange resin in lieu of a strongly acidic cation exchange resin. As will be described in greater detail with reference to the Detailed Description of the Invention, the effective application of a weakly acidic cation exchange resin in a mixed bed system is contrary to the results one skilled in the art would expect upon reviewing the published literature.

SUMMARY OF THE INVENTION

The present invention relates to a method for treating aqueous solutions such as recirculated condensate from turbine systems by ion exchange using a weakly acidic cation exchange resin and a strongly basic anion exchange resin to remove corrosion products and metal ion leakage from a solution while substantially reducing acid consumption in regeneration of the cation exchange resin. Substantial quantities of ammonia or volatile amines in the solution are not removed by the resins.

As used herein, the term "weakly acidic cation exchange resin" refers to a resin having an apparent dissociation constant or ionization constant (pK_(a)) greater than about 5.8 as measured by conventional methods. [See, for example, Fisher et al., J. Phys. Chem., 60, 1030 (1956)]. Weakly acidic cation exchange resins can exhibit a pKa in the range of about 3.5 to 6.5 or greater, but only such resins having a pKa greater than about 5.8 are useful in the present method. The term "strongly acidic cation exchange resin," on the other hand, refers to a resin having a pK_(a) less than about 3.5. The volatile amines removed from a solution passed through a mixed bed formed according to the present invention should have a pK_(b) less than about 5.0.

The method comprises:

(a) preparing a mixed bed of filter materials including a cation exchange resin and an anion exchange resin, the cation exchange resin having a pK_(a) greater than about 5.8; and

(b) passing a liquid through the mixed bed at a temperature less than 200° F. and at a linear flow rate less than 75 gallons per minute per square foot to substantially remove impurities from the liquid.

In an alternative embodiment, a porous support means can be precoated with a slurry comprising the above cation and anion exchange resins in a finely divided state to form a precoat layer. Thereafter the liquid can be passed through the precoat layer and the porous support means for purification. The porous support means can comprise a tubular or annular filter element, filter screen or filter bed. In a preferred embodiment, the precoat support means includes wound layers of yarn or other strand material including nylon, orlon, polypropylene, cotton and the like. The precoating step is accomplished as set forth in U.S. Pat. No. 3,779,386 to Ryan, which patent is assigned to the assignee of the present invention and which is incorporated herein by reference.

In preferred practice, the cation exchange resin is in the hydrogen form. By way of background, weakly acidic cation exchange resins have been prepared by a variety of procedures and encompass a large number of functional groups and structures. Functional groups can include carboxylic, phenolic, phosphonous and phosphonic entities of a rather wide range of acid strength. The most common weakly acidic cation exchange resins are those prepared by reacting an unsaturated carboxylic acid such as acrylic, methacrylic or maleic acid with a crosslinking agent such as divinylbenzene or ethylene dimethacrylate. Normally, an ester of the acid is used in the suspension polymerization process, and the acid ester is subsequently hydrolyzed.

The anion exchange resin of the present invention is preferably strongly basic and in the hydroxide form, with the ratio by dry weight of anion exchange resin to cation exchange resin being between 3 to 1 and 1 to 3.

Operation of a mixed bed system according to the present invention reduces the quantity of acid required to regenerate the weakly acidic cation exchange resin and the strongly basic anion exchange resin by a factor of more than 3 and minimizes the degree of sodium leakage relative to a mixed bed system comprising a strongly acidic cation exchange resin and a strongly basic anion exchange resin.

The total concentration of metal ions impurities remaining in the effluent after passage through the bed is less than about 10 parts per billion. In particular, the concentration of sodium ions in the effluent from the bed is less than about 1 part per billion when the influent concentration of sodium ions is about 100 parts per billion. This represents a removal of about ninety-nine percent. At the same time, relatively little ammonium ions and amines are removed from the solution.

Not all weakly acidic cation exchange resins are effective in the present method. Thus, the following description includes the criteria for selecting the proper weakly acidic cation exchange resins for use in the present invention from a number of commercially available resins.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph showing representative rinse down curves for a weakly acidic cation exchange resin having a pk_(a) less than about 5.8 (Dowex MWC-1) and a strongly acidic cation exchange resin (Dowex HGR W2).

FIG. 2 is a graph showing the effect of temperature on the run length of a weakly acidic cation exchange resin (Dowex MWC-1).

FIG. 3 is a graph showing the change in exchange capacity (kilograins per cubic foot) with temperature (° F.) for Dowex MWC-1 at equilibrium and at the breakthrough point.

FIG. 4 is a graph showing the change in equilibrium capacity (kilograins per cubic foot) and the percent utilization of the resin at the breakthrough point with temperature (° F.) for Dowex MWC-1.

FIG. 5 is a graph showing the pressure drop (pounds per square inch) as a function of temperature (° F.) for Dowex MWC-1.

FIG. 6 is a graph showing resin swelling (percent volume change) with temperature (° F.) for Dowex MWC-1.

DETAILED DESCRIPTION OF THE INVENTION

According to the present invention, weakly acidic cation exchange resins can be employed in a mixed bed or a precoat filter system including a strongly basic anion exchange resin to remove corrosion products and metal ion leakage, and can be completely regenerated with only a slight excess of acid. Strongly acidic cation exchange resins such as sulfonated styrene-divinylbenzene copolymer products, on the other hand, require a relatively large excess of acid for regeneration and, unless completely regenerated, such resins are prone to metal ion leakage and, in particular, sodium leakage.

The prior art, as exemplified by Simpson et al., Proceedings of the 44th International Water Conference, Engineer's Society of Western Pa. (Oct. 24-26, 1983), indicates that weakly acidic cation exchange resins exhibit poor small particle ion exchange kinetics whereas condensate polishing requires good ion exchange kinetics. In fact, the prior art does not even suggest the use of weakly acidic cation exchange resins for condensate polishing or under condensate polishing conditions; i.e., high flow rates (25-75 gpm/ft²) and low concentrations of total dissolved solids (TDS).

It is well known that strongly acidic cation exchange resins can effectively remove ammonia from water at both high and low concentrations. Moreover, weakly acidic cation exchange resins have been used to remove ammonia from various solutions having ammonia concentrations in excess of hundreds and thousands parts per million (ppm). However, there is little, if any, indication in the prior art that weakly acidic cation exchange resins are capable of effectively removing corrosion products and metal ion leakage from the condensates of high purity condensates such as those encountered in the industrial power applications while removing only a relatively small quantity of ammonia or volatile amines from the condensate.

In addition, while it would be advantageous to use weakly acidic cation exchange resins whenever possible because of their excellent regeneration efficiencies, the prior art indicates that such cation exchange resins would not be effective at removing cations such as sodium ions from condensates, particularly at elevated temperatures. For that matter, the same prior art would suggest that it would be difficult to use a weakly acidic cation exchange resins to remove traces of any cation under these same operating conditions.

On pages 36-37 of Ion Exchange Resins, written by one of the inventors of the present invention, Robert Kunin, titration curves are used to illustrate that the effective capacity of a strongly acidic cation exchange resin is essentially unchanged with variations in ionic strength or metal ion concentration. However, that is not the case for a weakly acidic cation exchange resin. Further, one would also anticipate that monovalent cations such as sodium ions would only be effectively removed by such cation exchange resins in alkaline media having at least modest cation concentrations (greater than 100 ppm).

In reviewing the prior art, it is most important to appreciate the fact that strongly acidic cation exchange resins have been effectively used for removing ammonia and volatile amines from condensates. However, the regeneration efficiencies of such resins are poor and unless the resin is regenerated completely with copious quantities of acid, excessive sodium leakage will occur. From an efficiency standpoint, one skilled in the art might consider using a weakly acidic cation exchange resin; however, the prior art indicates that such resins do not perform well under condensate polishing conditions. In support of this point, it should be noted that both strongly and weakly acidic cation exchange resins have been commercially available for years; however, weakly acidic cation exchange resins have not been used for condensate polishing even though the need for such an efficient resin has long existed.

In selecting the proper cation exchange resin for removing corrosion products and metal ions but not ammonia or other amines from condensates, a cation exchange resin must have an acidity that is sufficiently low to permit regeneration with high efficiency but sufficiently high so as to effectively remove only the corrosion products and metal ions. The acidity of an ion exchange resin is usually expressed in terms of its pK_(a) value; i.e. the negative logarithm of the ionization constant, K_(a), of the cation exchange resin and can be expressed as follows:

    pK.sub.a =-log K.sub.a

The ionization constant K_(a) is a measure of the degree of ionization of the acid form of the cation exchange resin. The greater the value of the ionization constant, the greater is the acid strength. Of course, as the ionization constant increases, the pK_(a) will decrease. Hence, in terms of pK_(a), a cation exchange resin with as high a pK_(a) as possible should be used provided the resin is still able to remove corrosion products and metal ions at elevated temperatures as high as 140°-150° F.

If only carboxylic acid-type weakly acidic cation exchange resins are considered, the pK_(a) of the weakly acidic cation exchange resin should be greater than a value of about 5.8. If the pK_(a) is significantly less than about 5.8, ammonia and other volatile amines will also be removed from the solution.

In addition, temperature plays a significant role in the method of the present invention. As the temperature is increased, the overall operating capacity of the resin is decreased but the utilization of the equilibrium capacity is increased. These data can be used to ascertain the temperature above which use of the present method would be impractical. From the following examples, it can be seen that the present method can be operated efficiently at temperatures as high as 200° F. In preferred practice, the present method is performed at a temperature in the range of about 115°-140° F.

The following examples are intended to illustrate the present invention, and should not be construed as limiting since the scope of the invention is determined with reference to the appended claims.

EXAMPLE 1 (Runs 1-4)

Three weakly acidic exchange resins having pKas below about 5.8 strongly acidic cation exchange resin were evaluated for metal ion and ammonia removal capacity under typical condensate polishing conditions; specifically, at a relatively high flow rate, low inlet concentration of impurities and elevated temperature.

The three weakly acidic resins evaluated in this example were DUOLITE C-464 macroporous (Diamond Shamrock Chemical Co., Cleveland, Ohio), AMBERLITE IRC-84 gel (Rohm and Haas Co., Philadelphia, Pa.) and DOWEX MWC-1 macroporous (Dow Chemical Co., Midland, Mich.), are representative acrylic acid-divinylbenzene type cation exchange resins having pk_(a) s less than about 5.8. These resins were selected on the basis of excellent osmotic shock resistance and high capacity. Additional weakly acidic cation exchange resins that are suitable for use in the present invention include Lewatit CNP (Bayer, West Germany) and Ionac CC (Ionac Chemical Co., Birmingham, NJ).

DOWEX HGR W2 (Dow Chemical Co., Midland, Mich.) was selected for comparison purposes as a typical strongly acidic styrene-divinylbenzene type cation exchange resin having sulfonic acid active groups. Other suitable strongly acidic cation exchange resins include Dowex HGR-S (Dow Chemical Co., Midland, Mich.), Amberlite IR-120 (Rohm and Haas Co., Philadelphia, Pa.) and Ionac C-267 (Ionac Chemical Co., Birmingham, N.J.).

Columns having an internal diameter of 1.5 inches were each filled with a resin to an 18 inch bed height as a preliminary test of the efficiency of each resin. Single element pilot plant feed tanks and pumps were used to feed ammonia at a rate of 2 parts per million (ppm) in a solution maintained at a pH of 9.6 and a temperature of 80°-140° F. Ammonia influent and effluent conductivity were continuously monitored by conventional methods using a conductivity recorder. Flow meters and needle valves were used to monitor and control the flow rate through each column. This technique for controlling the flow rate was sometimes less than satisfactory since flow tended to drop off during the runs as the pressure increased. In general, however, flow conditions were approximately 0.4 gallons per minute (gpm), 33 gpm/ft² and 21 gpm/ft³. (See Table 1).

Dilute sulfuric acid (4-5% by weight) was used to regenerate each resin at a dosage approximately equal to four times (4×) the stoichiometric amount necessary for complete regeneration of the resin, except in three tests as shown in Table 1 in which 1.2× the stoichiometric amount was tested. Regeneration was done manually, using a separatory funnel to gravity feed the regenerant for a contact time of at least one hour. Each resin was rinsed at 1 gpm/ft², and the effluent was monitored using a Beckman conductivity bridge and a flow-through cell.

Capacities were calculated from run length, influent ammonia and effluent ammonia as determined by conductivity measurements. Calculated equilibrium capacities were verified where possible by determining the mass balance on spent regenerant using ammonia electrode and back titration techniques.

                  TABLE 1                                                          ______________________________________                                                                       Regen.                                                                         Level  Operating                                 Run No.                                                                               Resin.sup.1  Cycle No. (Percent)                                                                             Temp. (°F.)                        ______________________________________                                         1      Dowex HGR W2 1         400    80                                               Duolite C464 1         400    80                                        2      Dowex HGR W2 2         120    90                                               Amberlite IRC-84                                                                            1         400    90                                        3      Amberlite IRC-84                                                                            2         120    95                                               Dowex MWC-1  1         400    95                                        4      Dowex MWC-1  2         120    140                                              Amberlite IRC-84                                                                            3         400    140                                       ______________________________________                                          .sup.1 Resins were subjected to one exhaustion/regeneration cycle prior t      testing, except for Duolite C464 which was not precycled. Each resin was       used as received from the manufacturer with no screening or backwashing. 

Table 2 lists the results obtained for ammonia removal with the cation exchange resins under the foregoing conditions of low inlet concentration, relatively high flow rate and elevated temperature. The exchange capacity, pressure drop ( ΔP ) and run length were determined for each resin.

Under the column in Table 2 entitled "Run Length", the subheading "Break" refers to the breakthrough point which is the time (usually expressed in hours) during operation of the bed at which some of the material to be adsorbed by the resin passes through the entire depth of the bed without being adsorbed and appears in the effluent. After the breakthrough point, the effluent concentration of the material to be adsorbed by the resin increases with time until it equals the concentration of that material at the inlet of the bed. At this time, the entire bed has a sorbed-phase concentration in equilibrium with the effluent concentration, and the bed is referred to as being exhausted. In a similar manner, under the column entitled, "Capacity", the subheading "Break" refers to the breakthrough ion exchange capacity (equivalents per liter) of the resin tested.

                                      TABLE 2                                      __________________________________________________________________________     Cycle    Temp.                                                                              Capacity.sup.1 (eq/l)                                                                  ΔP (psi)                                                                        Run Length (hrs)                                   Resin                                                                               No. (°F.)                                                                       Break                                                                              Equil.                                                                             Initial                                                                            Final                                                                             Break                                                                              Equil                                          __________________________________________________________________________     HGR W2                                                                              1   80  1.73                                                                               1.85                                                                               4.4 4.4                                                                               74  99                                                  2   80  0.90                                                                               0.95                                                                               4.2 4.2                                                                               40  50                                             C-464                                                                               1   80  0.92                                                                               1.33       41  66                                             IRC-84                                                                              1   90  1.28                                                                               1.42                                                                               6.0 14.5                                                                              48  76                                                  2   90  1.23                                                                               1.37                                                                               9.5 17 48  81                                                  3   140 1.46                                                                               1.59       45  67                                             MWC-1                                                                               1   90  1.48                                                                               1.60                                                                               6.5 10.5                                                                              62  91                                                  2   140 1.51                                                                               1.63       52  74                                             __________________________________________________________________________      .sup.1 Calculated capacities are expressed as equivalents per liter.           Several values were verified by mass balance measurements on the spent         regenerant.                                                              

Good ion exchange capacities were obtained with Amberlite IRC-84 and Dowex MWC-1; 28 and 32 kilograins per cubic foot (kgr/ft³), respectively, to an ammonia breakthrough at 90° F. These capacities represent approximately 30% of the total exchange sites on Amberlite IRC-84 and approximately 38% for Dowex MWC-1. The 38 kgr/ft³ capacity obtained for the strongly acidic cation exchange resin Dowex HGR W2, is approximately 78% of its total available exchange sites.

Duolite C464, which had a low breakthrough capacity, 20 kgr/ft³ (approximately 36% of the total exchange sites), did not rinse down after regeneration and was eliminated from further testing. High capacities were retained after 120% regeneration of both Amberlite IRC-84 and Dowex MWC-1 and both resins showed reasonable conductivity upon rinse down.

FIG. 1 is a comparison of representative Dowex MWC-1 and Dowex HGR W2 rinse curves. Although Dowex MWC-1 required a greater rinse volume (about 2.5 bed volumes) than Dowex HGR W2 (about 1.7 bed volumes) to effect an effluent conductivity of 100 micromhos, the two curves were very similar after 6 bed volumes of rinse. For example, the rinse volume requirement to achieve an effluent conductivity less than 10 micromhos was about 7.5 bed volumes for Dowex MWC-1 and about 8.5 bed volumes for Dowex HGR W2.

The high capacities obtained for both resins at 140° F., compared to the capacities obtained at 90° F., may be due either to the lower area flow rate which would mask the temperature effect observed in a later testings or to inaccurately controlled flow rate throughout the preliminary testing.

As expected, Amberlite IRC-84 and Dowex MWC-1 developed a high pressure drop during exhaustion as compared to Dowex HGR W2. After 72 hours of operation, after which approximately 90 percent of each resin was exhausted, the pressure drop for Dowex MWC-1 was 10.5 psi (pounds per square inch) and for Amberlite IRC-84 was 15 psi, which is a change from an initial reading of 6 psi. Dowex HGR W2 remained at 4.5 psi throughout the entire run.

EXAMPLE 2 (Runs 5-11)

Based on the results of Example 1, Dowex MWC-1 was selected for further testing (see Table 3). A pilot plant, with a 4 inch internal diameter column, was operated under conditions similar to those described in Example 1, but at a bed height of 36 inches and with an increased flow rate: 50 gpm/ft² (the volumetric flow rate expressed in terms of gpm/ft³ remained the same as in Example 1).

The flow rate was regulated with a control valve and was verified with a flow meter, so that the flow rate remained relatively constant during each run. Sodium removal was evaluated in Runs 10 and 11, with influent and effluent sodium being measured with an Orion SLED analyzer. The effect of temperature was determined over the range of 100° to 140° F.

                  TABLE 3                                                          ______________________________________                                                                      Operating                                                                              Actual                                    Run  Dowex MWC-1             Temp.   Bed Height                                No.  Resin         Cycle No. (°F.)                                                                           (Inches)                                  ______________________________________                                         5    screen, backwash                                                                             1         140     33                                        6    same resin #5 2         140     33                                        7    same resin #6 3         120     33                                        8    as received   1         100     36                                        9    same resin run #8                                                                            2         120     36                                        10   same resin run #9                                                                            3         140     36                                        11   same resin run #10                                                                           4         120     36                                        12   same resin run #11                                                                           5          90     18                                             backwashed                      and                                            SBR1, as received                                                                            1                 18                                        ______________________________________                                    

Table 4 lists the results obtained with Dowex MWC-1 over the temperature range 100° to 140° F. As previously indicated, a higher flow rate (50 gpm/ft²) was used in these runs as compared to the runs of Example 1. Ammonia influent, however, remained the same at 2 ppm and the pH of the ammonia feed solution was 9.6. Sodium removal was also investigated.

Temperature, as expected, had a marked effect on resin performance, affecting equilibrium capacity and thereby run lengths, as well as extent of utilization at the ammonia breakthrough point. Temperature did not appear to directly effect effluent quality. Ammonia concentrations in the effluent during each run ranged from 3 to 11 ppb as NH₃, conductivity from 0.07 to 0.14 micromhos (adjusted to 25° C.) and pH between 5 to 6.

                  TABLE 4                                                          ______________________________________                                         (Runs 5-9)                                                                     DOWEX MWC-1                                                                    Run No.    5        6        7     8     9                                     ______________________________________                                         Temperature (°F.)                                                                  140      137      120   100   119                                   Bed Height 33.5     32       32    36    36                                    (inches)                                                                       Influent NH.sub.3                                                                         1.9      2.2      2.2   2.2   2.1                                   (ppm as NH.sub.3)                                                              Effluent NH.sub.3                                                                          6-11    7-9      3     7     7                                     (ppb)                                                                          Effluent   0.09-0.14                                                                               0.10-0.12                                                                               0.055 0.10  0.10                                  conductivity                                                                   (micromhos)                                                                    Effluent pH                                                                               5.6      --       --    5.2-5.6                                                                              4.6-5.7                               Run length (hrs)                                                               to break   49       45       58    79    60                                    to equil.  61       56       70    120   88                                    Capacity (eq/l)                                                                at break   0.823    0.854    1.10  1.28  1.04                                  at equil.  0.905    0.970    1.34  1.79  1.24                                  ΔP initial (psi)                                                                    10       13       15    27    30                                    ΔP final.sup.1 (psi)                                                                21       21       21    41    37                                    exchange zone                                                                             6.6      6.3      5.5   12.3  11.5                                  (inches)                                                                       ______________________________________                                          .sup.1 For the equilibrated resin, the pressure drop (ΔP) was            relieved and was then remeasured to compensate for wall effects.         

FIG. 2 shows the run lengths obtained at various temperatures. Increasing the temperature from 100° F. to 140° F. reduced the run length by about 50 percent. Temperatures higher than 140° F. are not expected under normal operating conditions. However, at temperatures over 140° F., the capacity (and run length) of the resin gradually decreases, and the resin would eventually be thermally regenerated with little or no ammonia capacity.

FIGS. 3 and 4 show the effect of temperature on equilibrium capacity, breakthrough capacity and utilization. As the equilibrium capacity is reduced with increasing temperature, utilization at the breakthrough point is increased due to increased ion exchange kinetics.

FIG. 5 shows the pressure drop (as ΔP) in pounds per square inch versus operating temperature in °F. for Dowex MWC-1.

Resin bead swelling, upon conversion of Dowex MWC-1 from the hydrogen to the ammonia form, at different temperatures, is shown in FIG. 6. The apparent dependence of swelling on temperature is more likely a function of the extent of exhaustion, since equilibrium capacity varies with temperature in the same manner as swelling.

As indicated in Table 5, a substantial quantity of sodium ions were removed from a solution by Dowex MWC-1 under the conditions tested. Influent sodium ion concentrations of 100 ppb (in Run Number 10) at 140° F. and 550 ppb (in Run Number 11) at about 120° F. were reduced to approximately 0.4 ppb and 1 ppb, respectively. In both cases, sodium removal was independent of the ammonia breakthrough point, the sodium breakthrough point occurring well after the ammonia breakthrough point. Table 5 also summarizes the results obtained upon sodium and ammonia loading at the ammonia breakthrough point, the ammonia equilibrium point and the sodium breakthrough point.

                                      TABLE 5                                      __________________________________________________________________________     (Runs 10-12)                                                                   Run No.         10      11    12                                               __________________________________________________________________________     Temperature (°F.)                                                                       140     118   90                                               Bed Height (inches)                                                                            36      26    36                                               Influent NH.sub.3 (ppm NH.sub.3)                                                               2.3     2     2.0                                              Influent Na (ppb Na)                                                                           100     550   50                                               begun at (hours)                                                                               22      8     0                                                Effluent NH.sub.3 (ppb)                                                                        <10     <10   <10                                              Na(ppb) (±0.1)                                                                              0.4     1     0.5                                              Conductivity (micromhos)                                                                       0.12-0.14                                                                              3.4-4.3                                                                              0.12                                             pH              4.8-5.4 5.0-5.9                                                                              Neutral to MO, P                                 Run Length to NH.sub.3 break (hrs)                                                             48      70    40                                               to NH.sub.3 equil. (hrs)                                                                       67      100   78                                               to Na break     >66     95    60                                               to Na equil.    >70     >120  >120                                             Loading (eq/l) at NH.sub.3 break                                               NH.sub.3        0.0897  0.82  1.40                                             Na              0.016   0.205 0.050 est.                                       Total           0.913   1.03  1.45                                             Loading (eq/l) at NH.sub.3 equil.                                              NH.sub.3        1.15    0.978 2.04                                             Na              0.026   0.304 0.098                                            Total           1.18    1.28  2.14                                             Loading (eq/l) at Na break                                                     NH.sub.3        1.15    0.978 2.04                                             Na              0.026   0.313 0.089                                            Total           1.18    1.55  2.13                                             Loading at end of run                                                          NH.sub.3        1.15    0.978 2.04                                             Na              0.026   0.457 0.098                                            Total           1.18    1.44  0.098                                            K.sub.b.sup.1 (equilibrium)                                                                    not equilibrated                                                                       0.70  0.79                                             ΔP Initial (psi)                                                                         26      20    5                                                ΔP Final (psi)                                                                           38      54    15                                               __________________________________________________________________________      .sup.1 K.sub.b = (RNa) (NH.sub.4.sup.+)/(RNH.sub.4) (Na+)                

While the mechanism of sodium removal is not entirely clear, it appears from the data obtained in these runs that prior to the ammonia breakthrough point, sodium is exchanged to the detriment of ammonia removal; i.e., ammonia leakage should be equivalent to the amount of sodium removed.

The data in Table 5 demonstrates that the use under condensate polishing conditions of weakly acidic cation exchange resin having a pK_(a) less than about 5.8 effectively removed both sodium ions and ammonia from a condensate solution. In particular, the removal of sodium ions and ammonia was greater than 99% at temperatures from 90° to 140° F.

EXAMPLE 3 (Run 12)

The performance of a mixed bed system comprising a 1 to 1 volume ratio of Dowex MWC-1 and a strongly basic styrene-divinylbenzene type anion exchange resin having quaternary ammonium active groups [Dowex SBR-P (Dow Chemical Co., Midland, Mich.] was determined. Other suitable strongly basic anion exchange resins of the same type as Dowex SBR-P include Dowex SBR (Dow Chemical Co., Midland, Mich.), Amberlite IRA-400 (Rohm and Haas Co., Philadelphia, PA) and Ionac X-220 (Ionac Chemical Co., Birmingham, NJ).

The mixed bed system was operated under the same conditions and influent ammonia concentrations as those described in Example 2 and was evaluated for ammonia and sodium removal capacity. The weakly acidic cation exchange resin should comprise at least 25 percent (dry weight) of the total bed volume. As in Example 2, the bed height was 36 inches. However, 50 ppb Na feed using a sodium chloride solution was employed.

Sodium leakage was about 0.5 ppb (±0.1) until the sodium breakthrough point was reached at about 60 hours. That was long after the ammonia breakthrough point which occurred at 40 hours. Ammonia leakage during the run was estimated to be 6 ppb or less based on the effluent conductivity. The effluent conductivity at 24° C. was 0.12 micromhos prior to the ammonia breakthrough point with a cation conductivity at 0.06 micromhos and an anion conductivity unchanged at 0.12 micromhos. This indicates that no measurable chloride (anion) leakage took place but that some ammonia leakage occurred.

Thus, mixed bed operation with a weakly acidic cation exchange resin and a strongly basic anion exchange resin resulted in low effluent concentrations of cations, anions and amines (primarily, sodium ions, chloride ions and ammonia, respectively). In particular, the removal of sodium ions and ammonia was greater than 99% at temperatures from 90° to 140° F.

Compared to the single bed operation described in Example 2, the pressure drop was much less with the mixed bed system, due in part to a slight clumping of the mixed resins. An initial pressure drop of 5 psi increased to 15 psi at ammonia equilibrium. Bed expansion appeared minimal, due to a decreased volume of the weakly acidic cation exchange resin volume and to clumping which resulted in a larger void volume. (Dowex SBR-P without "anticlump" was used.)

After equilibrium, the anion and cation exchange resins were still clumped and could not be separated by merely backwashing with water. However, backwashing with an aqueous 10% (by weight) sodium chloride solution resulted in excellent (almost 100%) separation of the two resins.

EXAMPLE 4

One gram of dry ground (100-325 mesh) Amberlite IRC-50 (Rohm and Haas Co., Philadelphia, PA), a methacrylic acid-divinylbenzene type weakly acidic cation exchange resin having an ionization constant (pKa) of about 6.1, was prepared as an aqueous slurry with 1 gram of a dry, powdered strongly basic anion exchange resin in the hydroxide form [Powdex PAO (The Graver Company, Union, NJ)]. In a preferred embodiment, the weakly acidic cation exchange resin has a particle size in the range of about 1 to 150 microns. The slurry was prepared as a precoat filter as described in U.S. Pat. Nos. 3,250,703 and 3,779,386, which are assigned to the assignee of the present application and which are incorporated herein by reference.

Two condensate polishing runs were made at a flow rate of 4 gpm/ft² gallons per minute per square foot and at a temperature of 50° C. (approximately 122° F.) with condensate samples as described in Table 6. The effluent conductivity and thus the concentration of impurities in the effluent were measured after 4 hours by means of conductivity and acid conductivity techniques as previously described (after passage through a well-rinsed column of a strongly acidic type cation exchange resin). The data for these runs are presented in Table 6.

                                      TABLE 6                                      __________________________________________________________________________     CONDENSATE POLISHING RUNS WITH A PRECOAT FILTER                                INCLUDING A WEAKLY ACIDIC CATION                                               EXCHANGE RESIN (pKa 6.1)                                                                             INFLUENT             EFFLUENT                                                  ACID                 ACID                                RUN INFLUENT                                                                              INFLUENT   CONDUCTIVITY                                                                             EFFLUENT   CONDUCTIVITY                        NO. pH     Na(ppb).sup.1                                                                       NH.sub.3 (ppb)                                                                       (micromhos)                                                                              Na(ppb)                                                                             NH.sub.3 (ppb)                                                                       (micromhos)                         __________________________________________________________________________     1   9.6    400  2000  5.6       10   1500  0.07                                2   9.6    100  2000  1.4        1   1500  0.07                                __________________________________________________________________________      .sup.1 Added as an aqueous sodium chloride solution (10% of NaCl by            weight).                                                                 

As indicated in Table 6, the use under condensate polishing conditions of a weakly acidic cation exchange resins having a pKa of about 6.1, when combined with a strongly basic anion exchange resin to form a precoat filter, effectively removed sodium ions from a condensate solution, but removed only a relatively small amount of ammonia. In particular, the removal of sodium ions was greater than 97%, while only 25% of the influent ammonia was removed.

CONCLUSION

As described herein, a mixed bed ion exchange system or a precoat filter including a weakly acidic cation exchange resin having a pKa greater than about 5.8 and a strongly basic anion exchange resin substantially removes corrosion products and metal ions but not ammonia from a solution under condensate polishing conditions. That result would not be expected by one of ordinary skill in the art of ion exchange.

As shown in Table 6, ammonia added at a concentration of about 2000 parts per billion to the influent of a precoat filter formed according to the present invention was removed to concentrations in the effluent of less than 1500 parts per billion. Sodium ions, on the other hand, introduced to the influent at concentrations from 100 to 400 parts per billion were reduced to concentrations from 1 to 10 parts per billion after passage through the precoat filter. This represents much better than ninety percent removal of sodium ions from the influent with only a twenty-five percent removal of ammonia. The ammonia remaining in solution can be recycled. Those results were obtained for the described precoat filter upon operation at a temperature of about 50° C. (approximately 122° F.) and at a flow rate of about 4 gallons per minute per square foot.

The quantity of acid required to regenerate the cation exchange resin in a mixed bed was reduced by a factor of at least 3 relative to the quantity of acid required to regenerate the cation exchange resin of a mixed bed comprising a mixture of strongly acidic cation and strongly basic anion exchange resins. Moreover, in a mixed bed system the resins can be easily separated before regeneration by passage of a dilute salt solution (for example, a 10 percent sodium chloride solution) through the bed.

While the present invention has been described with reference to a particular embodiment, it will be understood that various changes and modifications can be made without departing from the spirit thereof, particularly as defined in the following claims. 

We claim:
 1. A method for selectively removing impurities including sodium ions from a liquid containing ammonia and sodium ions comprising the steps of:(a) preparing a bed of filter materials including a cation exchange resin and an anion exchange resin, said cation exchange resin having a pK_(a) greater than about 5.8; and (b) passing the liquid through the bed at a temperature less than 200° F. and at a flow rate of less than about 75 gallons per minute per square foot to substantially remove the sodium ion impurities and purify the liquid.
 2. The method according to claim 1 wherein the cation exchange resin is an acrylic acid-containing copolymer.
 3. The method according to claim 1 including the step of separating said resins by passing a second liquid upwardly through said resins to position said anion exchange resin in an upper layer and said cation exchange resin in a lower layer.
 4. The method according to claim 3 wherein the second liquid is an aqueous solution of a salt.
 5. The method according to claim 3 further including the steps of isolating said layers and passing an aqueous solution of a strong acid through the cation exchange resin to regenerate the cation exchange resin.
 6. The method according to claim 1 wherein the liquid is passed through the bed at a temperature in the range of about 80° F. to 190° F.
 7. The method according to claim 1 wherein the liquid is passed through the bed at a temperature in the range of about 115° F. to 140° F.
 8. The method according to claim 1 wherein the liquid is passed through the bed at a flow rate in the range of about 25 to 50 gallons per minute per square foot.
 9. The method according to claim 1 wherein the cation exchange resin is in the hydrogen form and the anion exchange resin is in the hydroxide form.
 10. The method according to claim 1 wherein the ratio by weight of anion exchange resin to cation exchange resin is between 3 to 1 and 1 to
 3. 11. The method according to claim 1 wherein the impurities include ammonia and volatile amines having pK_(b) less than about 5.0.
 12. The method according to claim 1 wherein, after the liquid is passed through the bed, the total concentration of sodium ion impurities remaining in the liquid is less than about 3 parts per billion.
 13. A method for selectively removing impurities including sodium ions from a liquid containing ammonia and sodium ions comprising the steps of:(a) preparing a mixed bed of filter materials including a cation exchange resin and an anion exchange resin, said cation exchange resin being a methacrylic acid-containing copolymer having a pK_(a) greater than about 5.8; and (b) passing the liquid through the bed at a temperature in the range of about 80° F. to 190° F. and at a flow rate in the range of about 25 to 50 gallons per minute per square foot to substantially remove the sodium ion impurities and to purify the liquid.
 14. The method according to claim 13 including the step of separating said resins by passing a second liquid upwardly through said resins to position said anion exchange resin in an upper layer and said cation exchange resin in a lower layer.
 15. The method according to claim 14 wherein the second liquid is an aqueous solution of a salt.
 16. The method according to claim 14 further including the steps of isolating said layers and passing an aqueous solution of a strong acid through the cation exchange resin to regenerate the cation exchange resin.
 17. The method according to claim 13 wherein the cation exchange resin is in the hydrogen form and the anion exchange resin is in the hydroxide form.
 18. The method according to claim 13 wherein the ratio by weight to anion exchange resin to cation exchange resin is between 3 to 1 and 1 to
 3. 19. The method according to claim 13 wherein the impurities include ammonia and volatile amines having a pK_(b) less than about 5.0.
 20. The method according to claim 13 wherein, after the liquid is passed through the bed, the total concentration of sodium ion impurities remaining in the liquid is less than about 3 parts per billion.
 21. A method for selectively removing impurities including sodium ions from a liquid containing ammonia and sodium ions comprising the steps of:(a) preparing a liquid slurry of filter particles in the range of about 1 to 150 microns including a cation exchange resin and an anion exchange resin, said cation exchange resin having a pK_(a) greater than about 5.8; and (b) precoating a porous support means with said slurry to form a precoat layer; and (c) passing the liquid through said precoat layer and said porous support means at a temperature less than 200° F. and at a flow rate of less than about 10 gallons per minute per square foot to substantially remove the sodium ion impurities and purify the liquid.
 22. The method according to claim 21 further including the step of passing an aqueous solution of a strong acid through said precoat layer and said porous support means to regenerate the cation exchange resin.
 23. The method according to claim 21 wherein the liquid is passed through said precoat layer and said porous support means at a temperature in the range of about 80° F. to 190° F.
 24. The method according to claim 21 wherein the liquid is passed through said precoat layer and said porous support means at a temperature in the range of about 115° F. to 140° F.
 25. The method according to claim 21 wherein the liquid is passed through said precoat layer and said porous support means at a flow rate in the range of about 1 to 10 gallons per minute per square foot.
 26. The method according to claim 21 wherein the cation exchange resin is in the hydrogen form and the anion exchange resin is in the hydroxide form.
 27. The method according to claim 21 wherein the ratio by weight of anion exchange resin to cation exchange resin is between 3 to 1 and 1 to
 3. 28. The method according to claim 21 wherein the impurities include ammonia and volatile amines having pK_(b) less than about 5.0.
 29. The method according to claim 21 wherein, after the liquid is passed through said precoat layer and said porous support means, the total concentration of sodium ion impurities remaining in the liquid is less than about 3 parts per billion.
 30. A method for selectively removing impurities including sodium ions from a liquid containing ammonia and sodium ions comprising the steps of:(a) preparing a liquid slurry of filter particles including a cation exchange resin and an anion exchange resin, said cation exchange resin being a methacrylic acid-containing copolymer having a pK_(a) greater than about 5.8; and (b) precoating a porous support means with said slurry to form a precoat layer; and (c) passing the liquid through said precoat layer and said porous support means at a temperature in the range of about 80° F. to 190° F. and at a flow rate in the range of about 1 to 10 gallons per minute per square foot to substantially remove the sodium ion impurities.
 31. The method according to claim 30 further including the step of passing an aqueous solution of a strong acid through said precoat layer and said porous support means to regenerate the cation exchange resin.
 32. The method according to claim 30 wherein the cation exchange resin is in the hydrogen form and the anion exchange resin is in the hydroxide form.
 33. The method according to claim 30 wherein the ratio by weight to anion exchange resin to cation exchange resin is between 3 to 1 and 1 to
 3. 34. The method according to claim 30 wherein the impurities include ammonia and volatile amines having a pK_(b) less than about 5.0.
 35. The method according to claim 30 wherein, after the liquid is passed through said precoat layer and said porous support means, the total concentration of sodium ion impurities remaining in the liquid is less than about 3 parts per billion. 